Non-halogen flame retardant polymers

ABSTRACT

Non-halogenated monomers that can be polymerized into flame retardant polymers, and processes to produce the monomers and polymers is provided. In a simplest aspect, there is provided a monomer composition that can comprise a) a group derived from one of a (meth)acrylic acid, (meth)acrylamide, or vinylbenzene, b) a polyphosphate moiety, and c) an amine species. In the monomer composition, the ethylenically unsaturated monomer of (a) is covalently bonded directly or through a linking group to the moiety of b), forming a precursor monomer unit. The amine species of c) is in complex with the precursor monomer unit. The polymer can be a homopolymer of the monomer composition, or a copolymer of the monomer composition having varying a), b) and c). In one embodiment, the polymer can additionally comprise ethylenically unsaturated monomers not covalently bonded to a polyphosphate moiety and/or can be cross-linked with a cross-linking agent such as resorcinol.

BACKGROUND OF THE INVENTION

The disclosed technology relates to non-halogen flame retardantcompositions comprising phosphorus in complex with nitrogen, andcross-linked by a cross-linking agent, such as resorcinol.

Halogens, i.e., fluorine, chloride, bromine and iodine, can be used infire retardant compositions. However, organic compounds containinghalogens can generate toxic substances, such as dioxin and difuran, uponcombustion. Organohalogens may also accumulate in the human body forlong periods of time and cause hormone problems. In addition, fluorine,chloride and bromine in particular, have been known to cause severedepletion of ozone. For this reason, the use of halogens, whether asflame retardants or in other applications, is increasingly regulated.Accordingly, there is a need for non-halogenated flame retardants.

One method of obtaining a flame retardant composition is to includephosphorus in the composition. For example, U.S. Pat. No. 5,281,239 toChatelin et al., issued Jan. 25, 1994, teaches a method of grafting afibrous material with phosphoric acid ethylenic esters of the generalformula:

the graft rate of the ester is taught to be less than or equal to 20%.

Similarly, U.S. Publication No. 2010/0261862 to Sugiyama et al.,published Oct. 14, 2010, teaches a method for grafting phosphoruscontaining compounds along with an amine compound onto a cellulosicfiber. The method relies on irradiating the fiber to create radicals towhich the phosphorus containing compound may bind.

JP2007182652A to Toshio, published Jul. 19, 2007, teaches flameretardant additives comprising a mixture of an organicphosphorus-base-flame-retarder and a nitrogen type flame retardant.Similarly, CN 102071032 teaches the use in combination of phosphoruscontaining and nitrogen containing flame retardants. These publicationsonly teach compounds containing tribasic phosphoric acid and do notteach polymerizing the compounds.

Polymer compositions containing a rubber modified vinyl resin, apolyphenylene ether resin, a cyclic alkyl phosphate compound, and anaromatic phosphate ester are taught in U.S. Pat. No. 7,829,629 to Ahn etal., issued Nov. 9, 2010. Similarly, U.S. Publication No. 2007/0192966to Cottrell et al., published Aug. 23, 2007, teaches flame retardantphosphorus containing polymers comprised of between 10 and 100 wt. % ofphosphorus containing monomer derived units. Neither of theaforementioned references teaches a polymer in which the monomers are incomplex with an amine species. These polymers would be highly acidic anddamaging to various substrates and thus, a transport concern.

A further problem exists in that some non-halogenated flame retardantpolymers do not remain coated on a surface if and when the surface iscontacted with water. For example, some surfaces are often contacted, orsubject to be contacted with tap water. If the flame retardant coatingwashes off with the tap water, the surface will lose its flameretardance.

A need exists for new non-halogenated flame retardants, and particularlynon-halogenated flame retardant polymers that less readily wash off withwater.

SUMMARY OF THE INVENTION

The inventors have discovered novel flame retardant (FR) monomers thatcan be polymerized into novel non-halogenated flame retardant polymers.

Thus, in a simplest aspect of the invention, there is provided a novelflame retardant monomer composition. The novel flame retardant monomercomposition can comprise a) a group derived from one of a (meth)acrylicacid, (meth)acrylamide, or vinylbenzene, b) a polyphosphate moiety, andc) an amine species. In the novel flame retardant monomer composition,an ethylenically unsaturated monomer of (a) is covalently bondeddirectly or through a linking group to the polyphosphate moiety of b),forming a precursor monomer unit. Further, the amine species of c) is incomplex with the covalently bonded polyphosphate moiety of b) in theprecursor monomer unit. In addition, the composition can be cross-linkedwith a cross-linking agent, such as resorcinol.

In one embodiment, the novel flame retardant monomer composition can beproduced by reacting the precursor monomer unit with the amine species.

In another aspect of the invention, there is provided a flame retardantpolymer. The flame retardant polymer can be a homopolymer of flameretardant monomeric units equivalent to, i.e., derived from, the novelflame retardant monomer composition, or a copolymer of monomeric unitsequivalent to the novel flame retardant monomer compositions havingvarying a), b) and c).

In one embodiment, the flame retardant polymer can additionally comprisemonomeric units equivalent to ethylenically unsaturated monomers thatare not covalently bonded to a polyphosphate moiety. In such anembodiment, at least 20% of the monomers in the polymer are monomericunits equivalent to the novel flame retardant monomer compositions ofthe simplest aspect of the invention, and from 0.1% to about 80% of themonomers in the polymer can be monomeric units equivalent to theethylenically unsaturated monomers that are not covalently bonded to apolyphosphate moiety. Such a copolymer can be comprised of at least 1wt. % P and have a number average molecular weight (Mn) of at leastabout 1000 g/mole.

In another embodiment of the invention, at least 90% of the monomers inthe flame retardant polymer can comprise a combination of monomericunits equivalent to the ethylenically unsaturated monomers that are notcovalently bonded to a polyphosphate moiety and monomeric unitsequivalent to the novel flame retardant monomer compositions of thesimplest aspect of the invention.

In one aspect of the invention, a flame retardant polymer can beproduced by several routes.

In one embodiment, the novel flame retardant monomer composition of thesimplest aspect can be free-radically polymerized to form a flameretardant polymer.

In another embodiment, the flame retardant polymer can be produced byfree radically polymerizing the precursor monomer units and subsequentlyreacting the polymerized product with the amine species.

In either embodiment of the process, ethylenically unsaturated monomerunits that are not covalently bonded to a polyphosphate moiety can be inincluded in the free radical polymerization.

In a further aspect of the invention, flame retardant compositions areprovided. The flame retardant composition can comprise the flameretardant polymers along with other additives. In particular, additivessuch as flame retardant additives and other polymers may be blended inthe flame retardant compositions along with the flame retardant polymer.

Also provided is a method of improving the capacity of a non-halogenflame retardant polymer to withstand tap water washing, comprisingpreparing the non-halogen flame retardant polymer with a cross-linkingagent.

Further, there is provided a method of maintaining flame retardance on asurface contacted or contactable with water, comprising applying to thesurface a polymer composition as disclosed herein, including across-linking agent.

DETAILED DESCRIPTION OF THE INVENTION

Various preferred features and embodiments will be described below byway of non-limiting illustration.

All ranges and ratio limits disclosed in the specification and claimsmay be combined in any manner. It is to be understood that unlessspecifically stated otherwise, references to “a,” “an,” and/or “the” mayinclude one or more than one, and that reference to an item in thesingular may also include the item in the plural.

The term “wt. %” means the number of parts by weight of ingredient per100 parts by weight of the composition or material of which theingredient forms a part.

As used herein, a polyphosphate moiety refers specifically to a groupcontaining a phosphorus atom bonded to three oxygen ions (phosphonate)or a phosphorus atom bonded to four oxygen ions (phosphate). Thepolyphosphate moiety may contain mono-, di-, tri-, or higher phosphate,or a mono-, and/or di-phosphonate, and in particular a monophosphate,diphosphate, triphosphate or monophosphonate. Preferrably thepolyphosphate moiety is a mono-, di-, or tri-phosphate.

As used herein, the term “hydrocarbyl substituent” or “hydrocarbylgroup” is used in its ordinary sense, which is well-known to thoseskilled in the art. Specifically, it refers to a group having a carbonatom directly attached to the remainder of the molecule and havingpredominantly hydrocarbon character. Examples of hydrocarbyl groupsinclude:

(i) hydrocarbon substituents, that is, aliphatic (e.g., alkyl oralkenyl), alicyclic (e.g., cycloalkyl, cycloalkenyl) substituents, andaromatic-, aliphatic-, and alicyclic-substituted aromatic substituents,as well as cyclic substituents wherein the ring is completed throughanother portion of the molecule (e.g., two substituents together form aring);

(ii) substituted hydrocarbon substituents, that is, substituentscontaining non-hydrocarbon groups which, in the context of thisinvention, do not alter the predominantly hydrocarbon nature of thesubstituent (e.g., halo (especially chloro and fluoro), hydroxy, alkoxy,mercapto, alkylmercapto, nitro, nitroso, and sulfoxy);

(iii) hetero substituents, that is, substituents which, while having apredominantly hydrocarbon character, in the context of this invention,contain other than carbon in a ring or chain otherwise composed ofcarbon atoms. Heteroatoms include sulfur, oxygen, nitrogen, andencompass substituents as pyridyl, furyl, thienyl and imidazolyl. Asused herein, an alkyl group containing an oxygen atom is referred to asan alkoxyl group.

The term “coating” is used herein to refer to impregnation, saturation,roller, brush, spray, foam and curtain coating and similar procedures.

The expression “( )” such as “(meth)”, “(alk)”, or “(alkyl),” is used toindicate that the particular substituent in a chemical name isoptionally present but may be absent. For example, the term“(meth)acrylate” may be used to refer to either acrylate ormethacrylate.

As used herein the term “polymer” refers to the product of apolymerization reaction in which the molecules of one or more monomersare linked together to form large molecules whose molecular weight is amultiple of that of the one or more monomers. These polymers may behomopolymers or copolymers. These polymers may be linear polymers,branched polymers, cross-linked polymers, or a mixture of two or morethereof.

The term “homopolymer” is used herein to refer to a polymer resultingfrom the polymerization of a single monomer.

The term “copolymer” is used herein to refer to a polymer resulting fromthe polymerization of two or more chemically distinct monomers.

The term “linear polymer” refers to a polymer in which the moleculesform long chains without branches or cross-linked structures.

The term “branched polymer” refers to a polymer in which the moleculesform a main chain or polymer backbone and one or more additionalrelatively short chains are attached to the main chain or polymerbackbone.

The term “cross-linked polymer” refers to a polymer in which the polymermolecules are linked to each other at points in their structures otherthan at the ends of the polymer chains.

The term “halogen-free” or “non-halogenated” polymer refers to a polymerthat does not have any halogen atoms attached to it. In one embodiment,the halogen-free polymer is a chlorine-free polymer. The term“halogen-free” does not exclude halogen that may be present atcontaminate levels, for example, levels of up to about 5% by weight, andin one embodiment up to about 2% by weight, and in one embodiment up toabout 1% by weight, and in one embodiment up to about 0.5% by weight,and in one embodiment up to about 0.2% by weight, and in one embodimentup to about 0.1% by weight.

It is recognized that when a monomer is polymerized, the resultantmonomeric unit within the polymer will have a structure that is slightlyaltered from the starting monomer. The monomeric unit is equivalent to,i.e., derived or derivable from, the starting monomer, having the sameatoms in the same relative positions to each other as in the monomer,only the carbon to carbon double bond of the monomer is converted to acarbon to carbon single bond in the monomeric unit and the excesselectrons from that conversion of the monomer are used to bond eachmonomeric unit to adjacent carbon atoms on an adjacent repeating unit ofthe polymer. It is to be appreciated that reference herein to a polymercomprising a monomer means that the polymer is comprised of monomericunits equivalent to, i.e., derived or derivable from, the monomer.

In a simplest aspect of the invention, there is provided a novel flameretardant monomer composition. The novel flame retardant monomercomposition can comprise a) an ethylenically unsaturated monomer, suchas, for example, a group derived from one of a (meth)acrylic acid,(meth)acrylamide, or vinylbenzene, b) a polyphosphate moiety, and c) anamine species. As used herein, vinylbenzene can be styrene or an alkylsubstituted vinylbenzene, such as, for example, α-methyl styrene,1-methyl-2-vinylbenzene, 1-methyl-3-vinylbenzene,1-methyl-4-vinylbenzene and the like.

As the ethylenically unsaturated monomer, there is also contemplated,for example, 2-hydroxyethyl (meth)acrylate (HEMA). Alternatively, othermonomers such as hydroxypropyl (meth)acrylate or 4-hydroxybutyl(meth)acrylate are contemplated. Likewise, 2-hydroxyethyl(meth)acrylamide, hydroxypropyl (meth)acrylamide, polyethyleneglycol(meth)acrylate and the like are contemplated.

In the novel flame retardant monomer composition, one of theethylenically unsaturated monomers of a) is covalently bonded directlyor through a linking group to the polyphosphate moiety of b), forming aprecursor monomer unit. Further, the amine species of c) is in complex,typically a salt, with the covalently bonded polyphosphate moiety of b)in the precursor monomer unit. Thus, although the ethylenicallyunsaturated monomers of a), the polyphosphate moiety of b) and the aminespecies of c) are disclosed separately, in the novel flame retardantmonomer composition the amine species are present in complex with thepolyphosphate moiety, and the polyphosphate moiety is covalently bondedto the ethylenically unsaturated monomers of a).

A flame retardant monomer is one that imparts flame retardancy to apolymer in which it is incorporated.

Example embodiments of the novel flame retardant monomer composition canbe, for example, phosphate esters of 2-hydroxyethyl methacrylatecomplexed with guanyl urea and phosphonic esters of 2-hydroxylethylmethacrylate complexed with guanyl urea. Without wishing to be bound bytheory, the novel flame retardant monomer composition may berepresented, for example, by the novel flame retardant monomercomposition of formula I.

In some embodiments of the invention, the term “derived” can meanderived or derivable. In some embodiments, the phosphorus containingmonomer can be derived or derivable from (meth)acrylic acid or(meth)acrylamide. By derivable, it is meant that derivation of themonomer is possible from (meth)acrylic acid or (meth)acrylamide, but mayalso be derived from other materials, such as other (meth)acrylic acidsources, for example, (meth)acrylonitrile in a Ritter reaction. Inanother example, the (meth)acrylic acid derived flame retardant monomercan be made using a (meth)acrylic acid ester. In such cases as theforegoing examples, the monomer product contains the (meth)acrylic acidor (meth)acrylamide moiety just the same as if it were derived from(meth)acrylic acid or (meth)acrylamide.

As noted above, a precursor monomer unit can be formed from apolyphosphate moiety and an ethylenically unsaturated monomer of a). Thepolyphosphate moiety can be a polyphosphate or monophosphonate compoundof formula —R₃X—[P(═O)(OR₅)O]_(n)R₄, or —R₃—P(═O)(OR₄)(OR₅), where:

X is O or NH,

R₃ is a C₀-C₅₀ hydrocarbyl linking group having oxygen and/or nitrogenatoms substituted for up to 20 of the carbon atoms,

n can be between about 1 to about 10, or about 1 to about 8, or about 1to about 6, and preferably from about 1 to about 3,

R₄ is H, M⁺, aryl or alkyl,

R₅ is H, or M⁺, and

M⁺ is a counterion selected from elements in Groups I and II of theperiodic table, or ammonium.

As used herein, ammonium means NH₄, or mono-, di-, tri-, ortetra-alkylammonium.

In some embodiments, the polyphosphate moiety can contain a tribasicacid of phosphorus. In some embodiments, the polyphosphate moiety can bederived from carboxyethyl monophosphate, carboxyethyl monophosphonate,carboamidoethyl monophosphate, carboamidoethyl monophosphonate,phenethyl monophosphate, or phenethyl monophosphonate.

Often, the precursor monomer unit, i.e., the unit comprised of the(meth)acrylic acid, (meth)acrylamide, or vinylbenzene covalently bondedto a polyphosphate moiety, may be purchased commercially, butnon-commercial precursor monomer units are also contemplated herein.Often commercial precursor monomer units are mixtures, such as, forexample, Sipomer™ PAM-4000 available from Rhodia, which is a major part2-hydroxyethyl (meth)acrylate monophosphate ester (HEMA) and a minorpart bis(2-hydroxyethyl (meth)acrylate) phosphate ester. Such mixturesare contemplated herein, as well as precursor monomer units that arepure compositions. HEMA polyphosphate can also be made directly fromHEMA and phosphorus pentoxide or phosphoric acid. Alternatively, othermonomers such as hydroxypropyl (meth)acrylate or 4-hydroxybutyl(meth)acrylate could be used in place of HEMA. Some other examples ofprecursor monomer units can include, polyethylene glycol (meth)acrylatephosphate ester (available as PAM-100 from Rhodia), polypropylene glycol(meth)acrylate phosphate ester (available as PAM-200 from Rhodia),methacrylamidoethyl phosphonic acid, vinylbenzene phosphonic acid, vinylphosphonic acid, and isopropenyl phosphonic acid.

In general, the amine species c) can have a molecular weight of fromabout 17 to about 3000 g/mole. Suitable amine species for the novelflame retardant monomer composition can be derived from, for example,dicyandiamide, alkylamines, such as, for example, trimethylamine,triethylamine, triethanolamine, and dimethylamine, or guanidine. Otherexamples of suitable amine compounds are urea, substituted akyl ureas,thiourea, akyl thiourea, cyanamide, ethylenediurea, aniline,ethyleneamines, guanidine, guanamine, benzoguanamine, acetoguanamine,glycoluril, acrylamide, methacrylamide, melamine, benzene sulfonamide,naphthalene sulfonamide, toluene sulfonamide, ammeline, ammelide,guanazole, phenylguanazole, carbamoylguanazole, dihydroxyethyleneurea,ethyleneurea, propylene urea, melem (C₆H₆N₁₀), melam (C₆H₉N₁₁),octadecylamide, glycine, and their mixtures. A specific example of asuitable amine species for use in the novel flame retardant monomercomposition can be guanyl urea, which can be derived from dicyandiamideand water.

Another aspect of the invention is a flame retardant polymer. In oneembodiment, the flame retardant polymers may be homopolymers orcopolymers comprising the novel flame retardant monomer compositions ofthe simplest aspect of the invention. In another embodiment, the flameretardant polymers may be a copolymer of A) at least one ethylenicallyunsaturated monomer unit that is not covalently bonded to apolyphosphate moiety, and B) the novel flame retardant monomercompositions of the simplest aspect of the invention. As a copolymer,the polymer can contain one or more of the same or differentethylenically unsaturated monomer units of A) and/or one or more of thesame or different novel flame retardant monomer compositions of B).

In one embodiment, the polymer can include a cross-linking agent.Crosslinking agents can include, for example, phenol derivatives, suchas dihydroxybenzenes, including resorcinol, hydroquinone, mono methylether hydroquinine, catechol and alkylated dihydroxybenzenes. Thecross-linking agent can be present from about 0.1 wt % to about 20 wt %of the polymer, or from 0.5 to about 15 wt %, or 1.0 to about 10.0 wt %.

The addition of a cross-linking agent often improves the ability of thepolymer to stay adhered to a surface, such as fibrous filtration media,after being washed by water, in particular non-demineralized water, suchas tap-water. In one embodiment, there is provided a method of improvingthe vertical burn performance of a non-halogen flame retardant polymerafter water soaking compared to the polymer without cross-linking, bypreparing the polymer with a cross-linking agent. The test for verticalburn is described below in Example 1. In another embodiment, there isprovided a method of improving the capacity of a non-halogen flameretardant polymer to withstand tap water washing, comprising preparingthe non-halogen flame retardant polymer with a cross-linking agent. In afurther embodiment, there is provided a method of maintaining flameretardance on a surface contacted or contactable with water, comprisingapplying to the surface a polymer composition as discussed herein,including a cross-linking agent.

In some embodiments, the ethylenically unsaturated monomer units of A)can be from 0% or 0.1% of the monomers in the polymer to about 80% ofthe monomers in the polymer. Likewise, up to about 65% of the monomersin the flame retardant polymer may be ethylenically unsaturated monomerunits of A). Alternately, up to about 70% or 75% of the monomers may bethe ethylenically unsaturated monomer units of A).

The ethylenically unsaturated monomer units of A) of the presentinvention can serve, among other things, to provide particular physicalcharacteristics to the polymer. Thus, one of ordinary skill in the artmay choose the appropriate ethylenically unsaturated monomer for theflame retardant polymer based on the particular physical characteristicsdesired for a particular application of the flame retardant polymer.

Some examples of ethylenically unsaturated monomers not covalentlybonded to a polyphosphate moiety suitable for use in the flame retardantpolymer can be, for example, one or more of, styrene, C₁-C₄₀ alkyl(meth)acrylates, C₁-C₄₀ (meth)acrylamides, acrylamide,N-methylolacrylamide (NMA), acrylonitrile, acrylic acid, methacrylicacid, itaconic acid, maleic acid, 2-acrylamido-2-methylpropane sulfonicacid, C₁-C₄₀ hydroxyalkyl (meth)acrylates, (acetoacetoxy)ethylmethacrylate, C₁-C₄₀ hydroxyalkyl (meth)acrylamide, diacetoneacrylamide, vinyl esters, butadiene, isoprene and dimeric ormulti-derivative compounds thereof. In addition, although the flameretardant polymer can be non-halogenated, halogenated ethylenicallyunsaturated monomers, such as, for example, vinyl chloride, are alsocontemplated herein as suitable ethylenically unsaturated monomer unitsof A) in the flame retardant polymers.

In the flame retardant polymer according to the invention, at least 20%of the monomers in the polymer are selected from the novel flameretardant monomer composition. It is also contemplated that up to 100%of the monomers making up the flame retardant polymer can be the novelflame retardant monomer composition. It is also contemplated that atleast 30%, at least 40%, or at least 50% of the monomers in the flameretardant polymer can be the novel flame retardant monomer composition.In certain flame retardant polymers according to the invention, at least35%, at least 45%, and at least 55% of the monomers may be the novelflame retardant monomer composition.

In some embodiments, at least 80%, or at least 85%, or at least 90%, andin some embodiments at least 95% of the monomers in the polymer comprisea combination of the ethylenically unsaturated monomers that are notcovalently bonded to a polyphosphate moiety and the novel flameretardant monomer compositions.

Preferably, the flame retardant polymer is comprised of at least 1 wt. %phosphorus and has a number average molecular weight (Mn) of at leastabout 1000 g/mole. In other embodiments, the flame retardant polymer maycontain phosphorus at from about 1 wt. % to about 15 wt. %, or fromabout 2 wt. % to about 14 wt. %, or from about 5 wt. % to about 10 wt.%. In one embodiment, the flame retardant polymer contains at least 7wt. % phosphorus and in another the flame retardant polymer containsabout, 9 wt. % phosphorus and in another 10.6 wt. % phosphorus.

The Mn of the flame retardant polymer should be at least 1000 g/mole.The Mn can also be from about 50,000 g/mole to about 1,000,000 g/mole,or from about 100,000 g/mole to about 750,000 g/mole. In one embodiment,the Mn of the flame retardant polymer can be about 200,000 g/mole toabout 500,000 g/mole.

Surprisingly, the flame retardant polymers comprised of novel flameretardant monomer compositions provide better flame retardantperformance than similar polymers that do not include apolyphosphate/amine species.

Process

In a preferred embodiment, the flame retardant polymer may be producedby first producing a mixture of at least one novel flame retardantmonomer composition, and subsequently free-radically polymerizing themixture to form a flame retardant polymer, for example, as shown informula II.

In addition, enough ethylenically unsaturated monomer units of A) can beadded to the polymerization mixture of the at least one novel flameretardant monomer composition so that the polymerization results in aflame retardant polymer in which 0% to about 80% (or about 0.1 to 75%,or 1 to 65% or 5 to 55%) of the monomers are ethylenically unsaturatedmonomer units of A) and at least 20% of the monomers are the at leastone novel flame retardant monomer composition. By employing theforegoing process, a flame retardant polymer can be produced wherein upto 80%, or up to 85%, or up to 90% of the monomer units in the polymercan be the novel flame retardant monomer composition. Likewise, up to95% or up to 100% of the monomer units in the polymer can be the novelflame retardant monomer composition.

The mixture of the at least one novel flame retardant monomercomposition can be produced, in one embodiment, by reacting a mixture ofat least one precursor monomer unit with a mixture of at least one aminespecies for between 10 minutes and 8 hours, preferably about 1 and 5hours, at a temperature of between about 20° C. and 100° C., preferably70° C. to 95° C., to form the mixture of the at least one novel flameretardant monomer composition.

In an alternate embodiment, the flame retardant polymer may be producedby first producing a pre-cursor polymer by free-radically polymerizingprecursor monomer units along with enough ethylenically unsaturatedmonomer units of A) to produce a polymer in which 0% to about 80% of themonomers are ethylenically unsaturated monomer units of A) and at least20% of the monomers are precursor monomer units. Subsequent topolymerization, the precursor polymer may be reacted with enough aminespecies to complex the polyphosphate moieties in the precursor monomerunits, as shown, for example, in formula III.

By employing the foregoing process, a flame retardant polymer can beproduced wherein up to 30%, or up to 35%, or up to 40% of the monomerunits in the polymer can be covalently bonded with polyphosphatemoieties.

In either process, a cross-linking agent, as discussed above, can beadded to the flame retardant composition mixture containing the flameretardant polymer. For example, resorcinol, i.e. dihydroxy benzene, canbe added to a completed reaction mixture containing the flame retardantpolymer.

Notably, a counterion may be introduced into the compound during pHadjustment. For example, NaOH, KOH, ammonium hydroxide or alkyl ammoniumhydroxide may be employed for pH adjustment, resulting in substitutionof the hydrogen of one or both of the hydroxyls with a counterion, suchas Na⁺, K⁺, ammonium, or alkyl ammonium.

In some embodiments, a polymerization catalyst or other standardcatalyst may be employed to assist polymerization. Examples ofpolymerization catalysts can be alkali metal hypophosphite salts, suchas sodium hypophosphite, alkali metal phosphites, alkali metalpolyphosphates, alkali metal dihydrogen phosphates, polyphosphoricacids, and alkyl phosphinic acids. In the case where a novel flameretardant monomer composition is produced and then polymerized, use of apolymerization catalyst can result in up to 95%, or up to 97.5%, or evenup to 100% of the monomer units in the polymer covalently bonded withpolyphosphate moieties. Likewise, in the case where polymerization takesplace prior to complexing, use of a polymerization catalyst can resultin up to 80%, or up to 85%, or up to 88%, or even up to 90% of themonomer units in the polymer covalently bonded with polyphosphatemoieties. Solvent can be employed at any point in the processes,including during addition and reaction of the vinyl monomers used in thepolymerization.

In either embodiment of the processes to produce the flame retardantpolymers, the mixture of the at least one precursor monomer unit can beobtained commercially, or by readily known processes to those ofordinary skill in the art.

In one embodiment the at least one precursor monomer unit can be madedirectly from the reaction of an alkoxyl (meth)acrylate with phosphoruspentoxide in water.

In the process to produce the flame retardant polymer, the polyphosphateto amine species (P:N) ratio in the amine species reaction step can befrom about 1:0.2 to about 1:15. The P:N ratio can also be from about1:0.5 to about 1:10, or from about 1:1 to about 1:5. Additionally, ineither embodiment, the amine species reaction step may be performed inthe presence of water. In particular, the reaction step may be completedby reacting the precursor monomer units or precursor polymer withdicyandiamide and water. The reaction with dicyandiamide and water willresult in the production of a guanyl urea, which guanyl urea can thencomplex with the polyphosphate moiety in the precursor monomer units.The complexation reaction may result in other by-products, whichby-products are contemplated herein.

In either embodiment, free radical polymerization or copolymerization ofthe monomers may be by any polymerization process, such as, for example,by dispersion polymerization, solution polymerization,photo-polymerization, or radiation polymerization. Emulsionpolymerization may be used. The monomers may be emulsified with ananionic, cationic, or nonionic surfactant or dispersing agent, orcompatible mixtures thereof such as a mixture of an anionic and anonionic surfactant, using, for example, from about 0.05% to about 5% byweight of a surfactant or dispersing agent based on the weight of themonomer. Suitable cationic dispersion agents include lauryl pyridiniumchloride, cetyldimethyl amine acetate, and alkyldimethylbenzylammoniumchloride, in which the alkyl group has from 8 to 18 carbon atoms.Suitable anionic dispersing agents include, for example, alkali fattyalcohol sulfates, such as sodium lauryl sulfate, and the like; arylalkylsulfonates, such as potassium isopropylbenzene sulfonate, and the like;alkali alkyl sulfosuccinates, such as sodium octyl sulfosuccinate, andthe like; and alkali arylalkylpolyethoxyethanol sulfates or sulfonates,such as sodium t-octylphenoxypolyethoxyethyl sulfate, having 1 to 5oxyethylene units, and the like. Suitable non-ionic dispersing agentsinclude, for example, alkyl phenoxypolyethoxy ethanols having alkylgroups of from about 7 to 18 carbon atoms and from about 6 to about 60oxyethylene units such as, for example, heptylphenoxypolyethoxyethanols; ethylene oxide derivatives of long chainedcarboxylic acids such as lauric acid, myristic acid, palmitic acid,oleic acid, and the like, or mixtures of acids such as those found intall oil containing from 6 to 60 oxyethylene units; ethylene oxidecondensates of long chained alcohols such as octyl, decyl, lauryl, orcetyl alcohols containing from 6 to 60 oxyethylene units; ethylene oxidecondensates of long-chain or branched chain amines such as dodecylamine, hexadecyl amine, and octadecyl amine, containing from 6 to 60oxyethylene units; and block copolymers of ethylene oxide sectionscombined with one or more hydrophobic propylene oxide sections. Highmolecular weight polymers such as hydroxyethyl cellulose, methylcellulose, polyacrylic acid, polyvinyl alcohol, and the like, may beused as emulsion stabilizers and protective colloids. Alternatively, themonomers can be polymerized without a surfactant.

The polymerization may be initiated in the presence of a small particlesize preformed emulsion polymer (e.g., seed polymerization), orunseeded. Seeded polymerization may yield an aqueous dispersion of latexpolymer having more uniform particle size than unseeded polymerization.

Chain transfer agents may be used to control molecular weight andinclude mercaptans, polymercaptans, alcohols, and halogen compounds usedin the polymerization mixture in order to moderate the molecular weightof the polymeric binder. Generally, from 0% to about 3% by weight, basedon the weight of the polymeric binder, of C₄-C₂₀ alkyl mercaptans,mercaptopropionic acid, or esters of mercaptopropionic acid, may beused.

The polymerization process may comprise a batch process, continuousprocess, staged process, or a process involving any other method. Eachstage of a staged process may incorporate thermal or redox initiation ofpolymerization. A monomer emulsion containing all or some portion of themonomers to be polymerized in a given stage may be prepared using themonomers, water, and emulsifiers. A solution of initiator in water maybe separately prepared. The monomer emulsion and initiator solution maybe co-fed into the polymerization vessel over the course of the emulsionpolymerization of any stage of the process. The reaction vessel itselfmay also initially contain seed emulsion and further may additionallycontain an initial charge of polymerization initiator. The temperatureof the contents of the reaction vessel may be controlled by cooling toremove heat generated by the polymerization reaction or by heating thereaction vessel. Several monomer emulsions may be simultaneously co-fedinto the reaction vessel. When multiple monomer emulsions are co-fed,they may be of different novel flame retardant monomer composition. Thesequence and rates at which the monomer emulsions are co-fed may bealtered during the emulsion polymerization process. After addition ofthe first monomer emulsion(s) has been completed, the polymerizationreaction mixture may be held at some temperature for a time and/ortreated with a polymerization inhibitor prior to polymerization of thesubsequent monomer emulsion(s). Similarly, after addition of the finalmonomer emulsion(s) has been completed, the polymerization reactionmixture may be held at some temperature for a time and/or treated with apolymerization inhibitor before cooling to ambient temperature.

The pH of the polymers can be adjusted to about 3.0 to about 10.0 in thepremix or in the emulsion polymer with commonly used base, such as, forexample, ammonium hydroxide, sodium or potassium hydroxide, magnesiumhydroxide, tri(m)ethylamine and the like.

Flame Retardant Compositions

The flame retardant polymers may contain conventional ingredients suchas solvents, plasticizers, pigments, dyes, fillers, emulsifiers,surfactants, thickeners, rheology modifiers, heat and radiationstabilization additives, defoamers, leveling agents, anti-crateringagents, fillers, sedimentation inhibitors, U.V. absorbers, antioxidants,flame retardants, etc. It may contain other polymeric species such asadditional polymers in the forms of blends, interpenetrating networks,etc.

In one embodiment, the flame retardant polymers may be blended withadditional flame retardant additives, which are well known in theliterature and art. Exemplary flame retardant additives includenon-halogen flame retardants, such as melamine and melamine derivatives,such as melamine cyanurate, melamine borate, melamine phosphate,melamine molybdate; borates; organic phosphates, organic phosphinatessuch as, for example, Exolit™ OP 1230 and 1311 available from Clariant,and phosphorus containing compounds, such as,9,10-dihydro-9-oxa-10-phosphaphenanthrene-10-oxide,tetrakis(hydroxymethyl)phosphonium chloride andbis[tetrakis(hydroxymethyl)phosphonium]sulfate; inorganic compounds suchas aluminum trihydrate, antimony oxide, ammonium phosphate, ammoniumpolyphosphate, calcium carbonate, clay, and talc. Although, in someembodiments, the flame retardant polymers are desired to benon-halogenated, blending the flame retardant polymers with halogenatedflame retardants, such as chlorinated and brominated compounds, such aspentabromodiphenyl ether, octabromodiphenyl ether, decabromodiphenylether, and hexabromocyclododecane, is contemplated herein. Often morethan one flame retardant is used and frequently 3 or more flameretardants are combined in flame retardant formulations. The level offlame retardants used in conjunction with the flame retardant polymersand copolymers of the present invention can be from about 1 to about 50parts by weight of flame retardant additive per 100 parts by weight ofthe flame retardant polymer.

Just as the ethylenically unsaturated monomers can be chosen to impartparticular physical properties to the flame retardant polymer,additional polymers can be blended with the flame retardant polymers andcopolymers of the present invention to produce blends of further flameretardancy or with certain physical properties. Examples of otherpolymers that may be blended can include polyurethane polymers,polyamide polymers, polyurea polymers, polyester polymers, polyacrylatepolymers, phenolic resins or mixtures thereof.

The polymer may be combined with other commercial polymers or polymerdispersions by methods known to those skilled in the art. The polymermay be used for forming hybrids with other polymers such as urethanes orsilicones. This may be done by polymerizing additional monomers byemulsion or suspension polymerization in the presence of the polymer,blending the polymer with other preformed polymers, or synthesizing thepolymer in the presence of other polymers.

In one embodiment, the polymer may be mixed with a phenolic resin in acondensation reaction, preferably containing 0.5-10 wt. % of N-methylol(meth)acrylamide (NMA).

Adjuvants useful in the preparation of the polymer and/or in itssubsequent use may be added during or subsequent to the polymerizationreaction. These may include auxiliary surfactants; defoamers such as,for example, SURFYNOL™ 104E and Nopco™ NXZ used at a level from about0.001 to about 0.1 wt. % based on the weight of the monomer mixture;leveling agents such as, for example, Sag™ Silicone Antifoam 47, used ata level from about 0.001 to about 0.1 wt. % based on the weight of themonomer mixture; antioxidants such as, for example, MAROXOL™ 20 andIRGANOX™ 1010 used at a level from about 0.1 to about 5 wt. % based onthe weight of the monomer mixture; plasticizers such as, for example,FLEXOL™ plasticizer; and preservatives such as, for example, KATHON™ ata level of about 30 to about 45 parts per million (ppm), or PROXEL™ GXLat a level of about 300 to about 500 ppm.

Flame Retardant Applications

In one embodiment, the flame retardant compositions described above canbe employed as a coating for fibrous filtration media. Use of the flameretardant compositions have exhibited a particular advantage in fibrousfilter media by improving flame retardancy without negatively effectingthe air permeability or pressure drop through the fibrous filter. Thatis, fibrous filter media coated with the novel flame retardantcompositions have improved air permeability and exhibit lower pressuredrops than prior art flame retardant compositions.

Fibrous filtration media can include a) filtration fabric also known as“paper” or rolled goods; b) synthetic filtration fabrics often referredto as “non-wovens” such as polypropylene, polyethylene, polystyrene, andrelated polyolefins; fiberglass; glass microfibers; polyamides such asnylon (6 and 6/6), Kevlar, Nomex; polyesters such as Dacron;polyacrylates, polymethacylates, polyacryonitrile such as Orion,polyvinyl chlorides and related materials, such as Saran;polytetrafluoroethylene; polyurethanes; copolymers of the abovematerials; and combinations thereof; c) natural filtration fabric suchas cellulose and other paper-based filtration media paper; wool; cotton;hemp; fiber glass; glass microfibers, carbon fibers; and combinationsthereof; and d) Woven fabric made from fibers such as cotton, nylon 6,polytetrafluorethylene (PTFE), nylon 6.6, nylon 11, nylon 12, halar(E-CTFE), polyester PBT, Polyester PET, polypropylene, acrylics,polyvinyl-den fluoride (PVDF), polyphosphate sulfide (PPS) and highdensity polyethylene, (e) filter aids such as adsorbents likediatomaceous earth, perlite, activated carbon, carbon black and relatedmaterials, anthracite, silicas, aluminas, and combinations thereof.Combinations of filter media can be used.

The types of filters that can be coated with the coating compositioninclude filter pads, filter bags, filter cartridges, pleated filters,membrane filters, strainers, screens, candle filters, plastic filters,ceramic filters, filter presses, belt filters, rotary drum filters, leaffilters, plate filters, disc filters, “precoat filters”, a filter bed ona strainer element or support, air filters, and the like.

The coated filters can be useful for the filtration of gases for theremoval of solid contaminants which are exemplified by dirt particles,dust, SiO₂, Al₂O₃, Fe₂O₃, CaO, MgO, Na₂O, K₂O, TiO₂, clays, solid metalparticles, carbon materials such as carbon black and activated carbon,particulates in industry, and combinations thereof, removal of odors,removal of toxic materials, and the filtration of other gases such asnitrogen, oxygen, carbon dioxide and the like, or flue gases, residualHg, SO₃ and the like and combinations thereof and the filtration ofaerosols, removal of acids (HIC, acetic acid, etc.). The filters may beantibacterial and antiviral.

The coated filter can be useful for the filtration of liquids for theremoval of water-insoluble contaminants such as solids contaminantswhich are exemplified by dirt particles, dust, SiO₂, Al₂O₃, Fe₂O₃, CaO,MgO, Na₂O, K₂O, TiO₂, clays, solid metal particles, carbon materialssuch as carbon black and activated carbon, particulates in industry, andcombinations thereof. The coated filter is useful for the removal ofliquid contaminants such as insoluble and non-miscible liquids such asaromatic compounds, hydrocarbons, halocarbons and combinations thereof.The coated filter is also useful for the removal of water-solublecontaminants such as water-soluble metal ions and metal oxides such asHg, Cu, H₃AsO₃, H₃AsO₄, Pb, Cd, Ba, Be, Se, and the like; acids such ascarboxylic acids, inorganic acids such as sulfuric acid), bases such asmetal hydroxides, metal bicarbonates and carbonates; amines; solublechemical contaminants such as amines, sulfur compounds, phosphoruscompounds, unsaturated compounds, phenols, MTBE (methyl t-butyl ether),chlorocarbons (and other halocarbons); aromatic compounds such asphenols, alcohols, and the like; gases such as CO₂, SO₂, H₂S; odorousmaterials and combinations thereof. Furthermore, the coated filter on afiltration media is useful for the removal of fluid-insoluble particlescontaminants such as by dirt (SiO₂, etc.); wear debris in engines andmachinery; as CaO particulates in the manufacture of detergents; carbonblack and activated carbon in manufacturing such as in thepharmaceutical industry; soot and other carbon-based solids in engineoils and combinations thereof.

The flame retardant polymers can be added to fibrous filter media by anyconventional means, for example, by impregnation, saturation, foamcoating, spraying, dipping or other coating procedure after preparing athread, woven cloth, or nonwoven fabric from fibers, or kneading orblending with a synthetic polymer fiber in melting, extruding andspinning processes. A method of introducing a flame retardant bychemical bonding, such as covalent bonding in preparing polymer may alsobe employed.

The flame retardant compositions described herein exhibit advantagesover prior art compositions employed as coatings on fibrous filtermedia. The coatings can provide flame retardancy at lower pickup levelsthan some prior art fibrous filter coatings. Fibrous filter coatings ofthe flame retardant compositions do not significantly affect filtrationefficiency, noticeably increase pressure, or decrease flow rate throughthe filter. Moreover, the compositions are not easily removed by water,as exemplified below where the coating composition maintains flameretardancy even after the filter upon which the composition is coated isrepeatedly washed with water.

It is known that some of the materials described above may interact inthe final formulation, so that the components of the final formulationmay be different from those that are initially added. The productsformed thereby, including the products formed upon employing thecomposition of the present invention in its intended use, may not besusceptible of easy description. Nevertheless, all such modificationsand reaction products are included within the scope of the presentinvention; the present invention encompasses the composition prepared byadmixing the components described above.

EXAMPLES Sample 1 Flame Retardant (“FR”) Polymer with Resorcinol

HEMA (272.48 g, 2.10 mole) and butylated hydroxytoluene (BHT) (0.16 g)are placed in a 1 liter 3-neck reactor. Phosphorous pentoxide (148.82 g,1.05 mole) is added in portions under air to keep the temperature below60° C. The reaction is then heated under air with an oil bath to 60° C.for 2 hours. The oil bath is removed and demineralized (“DM”) water (20g, 1.2 mole) is added slowly to keep temperature below 60° C. Themixture is heated at 60° C. for one more hour. The oil bath is removedand dicyandiamide (176.06 g, 2.10 mole) is added in portions to keeptemperature below 70° C., followed by DM water (44 g, 2.44 mole). Afterthe exotherm subsides, the reaction is heated under air to 90° C. for 3hours before cooling down to 60° C. 320 g DM water is then added to makean aqueous solution.

A mixture of 400 g of the solution prepared as described above, 114 gstyrene, 52 g 2-ethylhexylacrylate and 28 g NMA was adjusted to pH 4.2with 6.24 g 28% ammonium hydroxide and rinsed with 20 g DM water toobtain a premix. 700 g DM water is heated to 75° C. under nitrogenatmosphere and 2 g ammonium persulfate (APS) in 20 g water is added inone shot. When the temperature returns to 75° C., the aforementionedpremix is metered in over 80 minutes, then flushed with 20 g water. 30minutes later, 0.4 g APS in 8 g water was added and the polymerizationcontinued for 30 more minutes before cooling to 57° C. A redox initiatorof 1.2 g 70% t-butyl hydroperoxide (t-BHP) in 10 g DM water is addedfollowed by 0.64 g Bruggolite FF-6 in 12 g water. The mixture is stirredat 57° C. for 60 min. A second redox initiator of 0.6 g tBHP in 5 gwater followed by 0.32 g FF-6 in 6 g water. The mixture is allowed tocool while stirring. 1.5 g resorcinol was added and stirred for 30minutes at room temperature. The pH of the latex is 4.4.

Comparative 1 FR Polymer with 70% of Monomers being PAM-4000 in Complexwith Guanyl Urea

300 g Sipomer™ PAM-4000, 120 g dicyandiamide, 0.3 g BHT and 420 g waterare reacted at 90° C. for 2 hours. The product is mixed with 12 g of 48%NMA and 128.6 g ethyl acrylate (EA) to be pumped in 3 hours into areactor containing 775 g water and 60 g dicyandiamide initiated with 2.4g APS in 25 g water at 75° C., as described in previous examples. 12 gwater is used to flush the line. Additional 0.45 g APS in 12 g water isadded 30 minutes later. The mixture is stirred for 30 minutes beforecooling to 62° C. The mixture is redoxed twice with 0.31 g APS in 12 gwater and 0.31 g FF-6 in 20 g water before cooling down. The product isfiltered through a double layered cheese cloth with no apparentcoagulum.

Example 1 Control Vertical Burn Performance Data

Paper impregnated with a control composition of Hycar™ latex, which is acommercial latex composition available from The Lubrizol™ Corporation,is tested for flame retardancy. The control composition is also testedwith commercial flame retardant additives. PAM-4000 is also tested onits own as a cast film dried at ambient temperature and cured at 300° F.for 5 minutes. The controls are tested in a vertical burn test accordingto TAPPI 461, Apparatus 3.1 to 3.4, both before water soaking and afterbeing soaked in demineralized water for 24 hours and dried. Results areshown in Table 1.

TABLE 1 FLAME RETARDENCY VERTICAL Burn Before % water After□water Bindersoaking soaking Polymer Content 1st 2nd 1st 2nd PAM-4000 N/A CB CB n/an/a Hycar 26846 20.2-20.7 CB CB CB CB 100 parts Hycar 26846 + 100 partsPyrosan SYN 34.7 SE SE CB CB 100 parts Hycar 26846 + 100 partsNH₄Sulfomate 34.7 SE CB CB CB 100 parts Hycar 26846 + 100 partsAntiblaze LR3 33.9 SE SE CB CB 100 parts Hycar 26846 + 100 partsAntiblaze LR4 32.9 SE SE CB CB 100 parts Hycar 26846 + 100 partsAntiblaze MC 33.4 SE SE CB CB 100 parts Hycar 26846 + 100 parts MartinalOL-104 LE 32.4 CB CB CB CB 100 parts Hycar 26846 + 100 parts Melapur MP32.0 SE SE CB CB “SE” means self-extinguished and “CB” means completeburn. Pyrosan ™ SYN is an organic phosphate compound available fromEmerald Performance Materials. Antiblaze ™ LR3, LR4, and MC are ammoniumpolyphosphates available from Albemarle Corp. Martinal ™ OL-104 LE is analuminum hydroxide available from Albemarle Corp. Melapur ™ MP is amelamine phosphate available from DSM Melapur.

Example 2 Sample Vertical Burn Performance Data

Paper impregnated with Sample 1 and Comparative 1, are tested for flameretardancy. The compositions are tested in a vertical burn testaccording to TAPPI 461, Apparatus 3.1 to 3.4, both before water soakingand after being soaked in demineralized water and tap water. In eachcase, soaking was for an initial 2 hours, after which the sample wasremoved and the water bath was changed with fresh water and anothersoaking occurred for 2 more hours. Again, after the second 2 hours thebath was changed again with fresh water and another 2 hour soakoccurred. After the third 2 hour soak (6 hours total soak), the paperwas dried and tested for vertical burn. Soaking in tap water provides amore vigorous test of post water soaking performance. Results are shownin Table 2.

TABLE 2 Vertical Burn % Binder Before After DM Water After Tap ContentSoaking Soaking Water Soaking Comparative 1 31.2 SE SE CB Sample 1 31.4SE SE SE

Each of the documents referred to above is incorporated herein byreference. The mention of any document is not an admission that suchdocument qualifies as prior art or constitutes the general knowledge ofthe skilled person in any jurisdiction. Except in the Examples, or whereotherwise explicitly indicated, all numerical quantities in thisdescription specifying amounts of materials, reaction conditions,molecular weights, number of carbon atoms, and the like, are to beunderstood as modified by the word “about.” It is to be understood thatthe upper and lower amount, range, and ratio limits set forth herein maybe independently combined. Similarly, the ranges and amounts for eachelement of the invention can be used together with ranges or amounts forany of the other elements. As used herein, the expression “consistingessentially of” permits the inclusion of substances that do notmaterially affect the basic and novel characteristics of the compositionunder consideration.

1. A flame retardant monomer composition comprising: a) a group derivedfrom one of a (meth)acrylic acid, (meth)acrylamide, or vinylbenzene, b)a polyphosphate moiety, c) an amine species, and d) a cross-linkingagent; wherein a) is covalently bonded directly or through a linkinggroup to b) forming a precursor monomer unit, and wherein c) is incomplex with the covalently bonded polyphosphate moiety of b) in theprecursor monomer unit.
 2. The composition of claim 1 wherein thepolyphosphate moiety is derived from a polyphosphate or monophosphonatecompound of formula —R₃X—[P(═O)(OR₅)O⁻]_(n)R₄, or —R₃—P(═O)(OR₄)(OR₅),where: n is about 1 to about 10 X is O or NH, R₃ is a C₀-C₅₀ hydrocarbyllinking group having oxygen and/or nitrogen atoms substitute for up to20 of the carbon atoms, R₄ is H, or M⁺, R₅ is H, or M⁺, and M⁺ is acounterion selected from elements in Groups I and II of the periodictable or ammonium.
 3. The composition according to claim 1 wherein thepolyphosphate moiety is carboxyethyl monophosphate, carboxyethylmonophosphonate, carboamidoethyl monophosphate, carboamidoethylmonophosphonate, phenethyl monophosphate, or phenethyl monophosphonate,or mixtures thereof.
 4. A composition according to claim 1, wherein theprecursor monomer unit is selected from 2-hydroxyethyl (meth)acrylatemonophosphate ester, bis(2-hydroxyethyl (meth)acrylate diphosphateester, polyethylene glycol (meth)acrylate monophosphate ester,polypropylene glycol (meth)acrylate monophosphate ester,methacrylamidoethyl phosphonic acid, vinylbenzene phosphonic acid, vinylphosphonic acid, and isopropenyl phosphonic acid.
 5. The compositionaccording to claim 1 wherein the amine species has a molecular weight offrom about 16 to 3000 g/mole.
 6. The composition according to claim 1wherein the amine species is derived from dicyandiamide, an alkylamine,or guanidine.
 7. A composition according to claim 1 wherein the flameretardant monomer composition is 2-(phosphonooxy)ethyl methacrylatecomplexed with guanyl urea or (2-(methacryloyloxy)ethyl)phosphonic acidcomplexed with guanyl urea.
 8. A composition according to claim 1wherein the cross-linking agent is resorcinol, catechol, alkylateddihydroxybenzene, or mixtures thereof.
 9. A flame retardant polymercomprised of monomeric units equivalent to the flame retardant monomercompositions according to claim
 1. 10. The flame retardant polymer ofclaim 9, wherein the polymer is a homopolymer.
 11. The flame retardantpolymer of claim 9, wherein the polymer is a copolymer of the flameretardant monomer compositions having varying a), b) and c).
 12. Theflame retardant polymer according to claim 9, additionally comprisingethylenically unsaturated monomers that are not covalently bonded to apolyphosphate moiety.
 13. The flame retardant polymer of claim 11,wherein at least 20% of the monomers in the polymer are the flameretardant monomer compositions and from 0.1% to about 80% of themonomers in the polymer are the ethylenically unsaturated monomers thatare not covalently bonded to a polyphosphate moiety, and wherein thepolymer is comprised of at least 1 wt. % P and has a Mn of at leastabout 1000 g/mole; and wherein at least 90% of the monomers in thepolymer comprise a combination of the ethylenically unsaturated monomersthat are not covalently bonded to a polyphosphate moiety and the flameretardant monomer compositions, wherein said ethylenically unsaturatedmonomers that are not covalently bonded to a polyphosphate moiety areone or more of vinyl chloride, styrene, C₁-C₄₀ alkyl (meth)acrylates,C₁-C₄₀ (meth)acrylamides, acrylamide, N-methylolacrylamide (NMA),acrylonitrile, acrylic acid, methacrylic acid, itaconic acid, maleicacid, 2-acrylamido-2-methylpropane sulfonic acid, C₁-C₄₀ hydroxyalkyl(meth)acrylates, C₁-C₄₀ hydroxyalkyl (meth)acrylamide, vinyl esters,butadiene, isoprene and dimeric or multi-derivative compounds thereof.14. The polymer according to claim 9 wherein the phosphorus content isfrom about 1.0 to about 15.0 wt. % of the polymer.
 15. The polymeraccording to claim 9 wherein at least 50% of the monomers in thecomposition are selected from the flame retardant monomer compositions.16. A method of maintaining flame retardance on a surface contacted orcontactable with water, comprising applying to the surface a polymercomposition as claimed in claim
 9. 17. A composition comprising thepolymer according to claim 9, and further comprising from about 1 toabout 50 parts by weight of a flame retardant additive per 100 parts byweight of said flame retardant polymer.
 18. The composition of claim 17,wherein the flame retardant additive is one or more of a melaminederivative flame retardant, an organic flame retardant, an inorganicflame retardant, an organic phosphate, phosphonate or phosphinate flameretardant, a halogenated compound flame retardant, and mixtures thereof.19. The composition of claim 18, wherein the flame retardant additive ismelamine cyanurate.
 20. The composition of claim 17 additionally blendedwith one or more polyurethane polymers, polyamide polymers, polyureapolymers, polyacrylate polymers or mixtures thereof.
 21. A method ofimproving the capacity of a non-halogen flame retardant polymer towithstand tap water washing, comprising preparing the non-halogen flameretardant polymer with a cross-linking agent.